Electrode configuration for a biosensor

ABSTRACT

A biosensor including a capillary chamber having an inner boundary, a working electrode including an effective working electrode portion positioned within the capillary chamber, and a counter electrode including an effective counter electrode portion positioned within the capillary chamber, and with the working and counter electrodes each having a neck that constitutes the sole portion of the electrodes that extends across the inner boundary and out of the capillary chamber. In one embodiment, the effective working electrode portion defines an average working electrode width, and the working electrode neck defines a working electrode neck width that is reduced relative to the average working electrode width. In another embodiment, a ratio between the area of the effective working electrode portion exposed to the capillary chamber and the area of the effective counter electrode portion exposed to the capillary chamber is substantially constant as a position of the inner boundary of the capillary chamber is varied along a length of the working and counter electrode necks.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 13/837,083 filed Mar. 15, 2013, which is incorporated herein by reference in its entirety.

BACKGROUND

Electrochemical biosensors are known in the art and have been used to determine the concentration of various analytes from biological samples, particularly from blood. Various configurations of electrochemical biosensors are described in U.S. Pat. Nos. 5,413,690; 5,762,780; 5,798,031; 5,997,8171; 7,073,246; 7,195,805 and 7,473,398 and U.S. Patent Application Publication No. 2005/0016844, the disclosures of which are each expressly incorporated herein by reference in their entirety.

As the number of patients suffering from diabetes and similar medical conditions increases, self-monitoring of blood glucose where the patient monitors his or her blood glucose level has become common practice. The purpose of monitoring the blood glucose level is to determine the blood glucose concentration level, and then to take the requisite corrective action based on whether the level is too high or too low in order to bring the level back within a normal or acceptable range. Failure to take corrective action can result in serious medical implications. Glucose monitoring is a fact of everyday life for millions of diabetic individuals. Additionally, failure to test blood glucose levels properly and on a regular basis can result in serious diabetes-related complications, including cardiovascular disease, kidney disease, nerve damage and/or blindness.

A number of biosensors utilize electrochemical analysis to determine the blood glucose level by measuring a current that corresponds to an analyte concentration. Such biosensors may utilize a capillary chamber having an electrode substrate providing a working electrode area located in the capillary chamber. The current response of the electrochemical cell is directly proportional to the working electrode area. However, variations in the working electrode area may result from the manufacture and assembly of the components of the biosensor that define the capillary chamber and the position/location of the working electrode. Variations in the working electrode area in the capillary chamber from one biosensor to another are undesirable since such variations introduces imprecision and/or inaccuracy in the measured analyte concentration, which may in turn result in an imprecise and/or inaccurate measurement of the blood glucose level.

Therefore, biosensor arrangements which minimize variation in the working electrode area associated with the manufacture of the biosensor are desirable. Additionally, maintaining a balanced ratio between the counter electrode area and the working electrode area in the capillary chamber is also desirable in order to increase the precision and/or accuracy of the biosensor.

SUMMARY

The present invention generally relates to a biosensor, and more specifically relates to an electrode configuration for a biosensor having a relatively constant/balanced ratio between the counter electrode area and the working electrode area, and having a relatively low variation in the working electrode area.

According to one form, a biosensor is provided which includes a capillary chamber having an inner boundary, a working electrode including an effective working electrode portion positioned within the capillary chamber, and a counter electrode including an effective counter electrode portion positioned within the capillary chamber. The effective working electrode portion defines an average working electrode width and has a working electrode neck defining a working electrode neck width that is reduced relative to the average working electrode width. The working electrode neck constitutes the sole portion of the working electrode that extends across the inner boundary and out of the capillary chamber. The effective counter electrode portion has a counter electrode neck that constitutes the sole portion of the counter electrode that extends across the inner boundary and out of the capillary chamber.

According to another form, a biosensor is provided which includes a capillary chamber having an inner boundary, a working electrode including an effective working electrode portion positioned within the capillary chamber, and a counter electrode including an effective counter electrode portion positioned within the capillary chamber. The effective working electrode portion has a main body and a working electrode neck extending therefrom, with the working electrode neck constituting the sole portion of the working electrode that extends across the inner boundary and out of the capillary chamber. The effective counter electrode portion has a main body and a counter electrode neck extending therefrom, with the main body of the effective counter electrode portion positioned generally adjacent the main body of the effective working electrode portion, and with the counter electrode neck constituting the sole portion of the counter electrode that extends across the inner boundary and out of the capillary chamber.

According to another form, a biosensor is provided which includes a capillary chamber having an inner boundary, a working electrode including an effective working electrode portion positioned within the capillary chamber, and a counter electrode including an effective counter electrode portion positioned within the capillary chamber. The effective working electrode portion defines an effective working electrode area exposed to the capillary chamber, with the effective working electrode portion having a working electrode neck that constitutes the sole portion of the working electrode that extends out of the capillary chamber. The effective counter electrode portion defines an effective counter electrode area exposed to the capillary chamber, with the effective counter electrode portion having a counter electrode neck that constitutes the sole portion of the counter electrode that extends out of the capillary chamber. The working electrode neck and the counter electrode neck each extend across a single inner side wall defining the inner boundary of the capillary chamber, and a ratio between the effective working electrode area and the effective counter electrode area is substantially constant as a position of the single inner side wall is varied along a length of the working electrode neck and the counter electrode neck.

Further aspects, embodiments, forms, features, benefits, objects, and advantages shall become apparent from the detailed description and figures provided herewith.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a perspective view of a biosensor according to one form of the present invention.

FIG. 2 is a top plan view of the biosensor of FIG. 1.

FIG. 3 is a top plan view of the biosensor of FIG. 2 with the hydrophilic roof removed.

FIG. 4 is a top plan view of the biosensor of FIG. 3 with the spacer substrate removed.

FIG. 5a is cross-sectional view of a portion of the biosensor of FIG. 1, as take along view line 5 a-5 a of FIG. 2.

FIG. 5b is cross-sectional view of a portion of the biosensor of FIG. 1, as take along view line 5 b-5 b of FIG. 2.

FIG. 6 is an enlarged plan view of the distal end portion of the biosensor of FIG. 1 illustrating the capillary chamber and the electrode configuration positioned therein.

FIG. 7a is an enlarged plan view of the distal end portion of the biosensor of FIG. 1 illustrating a nominal placement of the spacer substrate relative to the support substrate and the electrode arrangement.

FIG. 7b is an enlarged plan view of the distal end portion of the biosensor of FIG. 1 illustrating a maximal placement of the spacer substrate relative to the support substrate and the electrode arrangement.

FIG. 7c is an enlarged plan view of the distal end portion of the biosensor of FIG. 1 illustrating a minimal placement of the spacer substrate relative to the support substrate and the electrode arrangement.

FIG. 8a is an enlarged plan view of a distal end portion of a comparative biosensor illustrating a nominal placement of a spacer substrate relative to a support substrate and an electrode arrangement.

FIG. 8b is an enlarged plan view of the distal end portion of the comparative biosensor illustrating a maximal placement of the spacer substrate relative to the support substrate and the electrode arrangement.

FIG. 8c is an enlarged plan view of the distal end portion of the comparative biosensor illustrating a minimal placement of the spacer substrate relative to the support substrate and the electrode arrangement.

FIG. 9a is an enlarged plan view of a distal end portion of a second comparative biosensor illustrating a nominal placement of a spacer substrate relative to a support substrate and an electrode arrangement.

FIG. 9b is an enlarged plan view of the distal end portion of the second comparative biosensor illustrating a maximal placement of the spacer substrate relative to the support substrate and the electrode arrangement.

FIG. 9c is an enlarged plan view of the distal end portion of the second comparative bio sensor illustrating a minimal placement of the spacer substrate relative to the support substrate and the electrode arrangement.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

For purposes of promoting an understanding of the principles of the present invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated herein being contemplated as would normally occur to one skilled in the art to which the invention relates.

The present invention generally relates to a biosensor, and more specifically relates to an electrode configuration for a biosensor having a relatively constant/balanced ratio between the counter electrode area and the working electrode area, as well as a relatively low variation in the working electrode area, to thereby improve the precision and/or accuracy of current measurements in the electrochemical analysis of an analyte positioned in a capillary chamber of the biosensor. Aspects and features of the biosensor are presented in FIGS. 1-7 which are not necessarily drawn to scale and where like components in the various drawing figures are numbered alike.

Referring to FIGS. 1-6, shown therein are various aspects and features of a biosensor 10 according to one form of the present invention. In the illustrated embodiment, the biosensor 10 has a proximal end 10 a and an opposite distal end 10 b arranged along a longitudinal axis L, and generally includes an electrode support substrate 12, an intermediate spacer substrate 14 positioned on the support substrate 12, and a cover substrate or hydrophilic roof 16 positioned on the spacer substrate 14. The support substrate 12, the spacer substrate 14 and the cover substrate 16 cooperate with one another to define a capillary chamber or channel 18 having a sample inlet port 19 for receiving a fluid sample adjacent the distal end 10 b of the biosensor 10. Additionally, the support substrate 12 includes an electrical conductor arrangement 20 including a series of electrodes 22, 24, 26 a and 26 b that each include one or more electrode portions positioned within the capillary chamber 18, further details of which will be set forth below. Although the illustrated embodiment of the biosensor 10 includes three separate substrates 12, 14 and 16 that are sandwiched together to form the capillary chamber 18, it should be understood that other embodiments are also contemplated including, for example, embodiments that do not include the cover substrate 16.

In the illustrated embodiment, the biosensor 10 is shown as having a rectangular configuration defining an overall length/extending generally along the longitudinal axis L between the proximal and distal ends 10 a, 10 b, and further defining an overall width w extending in a lateral direction generally along a transverse axis T. However, it should be understood that the biosensor 10 can be provided with other suitable shapes and configurations without departing from the principles of the present invention. It should be understood that the biosensor 10 can be any one of a substantial quantity of biosensors produced from rolls of material, sheets of material, or other material stock. In one embodiment, the selection of materials from which the biosensor 10 is constructed includes a stock sufficiently flexible for roll processing, but still rigid enough to provide a useful/sufficient stiffness to the biosensor 10. Additionally, the arrangement and configuration of the biosensor 10 and the manufacturing method associated with forming the biosensor 10 provides a relatively constant/balanced ratio between the counter electrode area and the working electrode area, as well as a relatively low variation in the working electrode area, to thereby improve the precision and/or accuracy of current measurements in the electrochemical analysis of an analyte positioned in the capillary chamber 18 of the biosensor 10, further details of which will be set forth below.

Referring collectively to FIGS. 4, 5 a, 5 b and 6, in the illustrated embodiment, the support substrate 12 has a rectangular configuration defining a length dimension substantially equal to the overall length/of the biosensor 10, and a width dimension substantially equal to the overall width w of the biosensor 10. The support substrate 12 includes a bottom/lower outer surface 30 defining an outer face of the biosensor 10, and a top/upper inner surface 32 facing a direction opposite the outer surface 30. Additionally, the support substrate 12 includes opposite first and second end surfaces or edges 34 a, 34 b extending generally along the transverse axis T (i.e., along the width dimension), and opposite first and second side surfaces or edges 36 a, 36 b extending generally along the longitudinal axis L (i.e., along the length dimension) between the end surfaces 34 a, 34 b. While the end surfaces 34 a, 34 b and the side surfaces 36 a, 36 b of the support substrate 12 are illustrated to form a generally rectangular shape, as indicated above, it should be understood that the biosensor 10, including the support substrate 12, may form other shapes and configurations without departing from the principles of the present invention. In one specific embodiment, the support substrate 12 is formed of a flexible polymer material including, for example, a polyester or polyimide such as polyethylene naphthalate (PEN). However, other suitable materials for the support substrate 12 are also contemplated.

As indicated above, the support substrate 12 includes an electrical conductor arrangement or ablated electrode pattern 20 including a series of electrodes 22, 24, 26 a and 26 b. The electrodes 22, 24, 26 a and 26 b are formed from an electrical conductor 28 extending along the inner surface 32 of the support substrate 12. Non-limiting examples of materials suitable for the electrical conductor 28 include aluminum, carbon (such as graphite), cobalt, copper, gallium, gold, indium, iridium, iron, lead, magnesium, mercury (as an amalgam), nickel, niobium, osmium, palladium, platinum, rhenium, rhodium, selenium, silicon (such as highly doped polycrystalline silicon), silver, tantalum, tin, titanium, tungsten, uranium, vanadium, zinc, zirconium, mixtures thereof, and alloys, oxides, or metallic compounds of these or other elements. In one specific embodiment, the individual electrodes 22, 24, 26 a and 26 b are isolated from one another via laser ablation or laser scribing, and the electrodes 22, 24, 26 a and 26 b may be created by removing select portions of the electrical conductor 28 from an area extending around/along the electrodes 22, 24, 26 a and 26 b either broadly, such as by broad field ablation, or minimally, such as by line scribing. However, it should be understood that other suitable techniques for forming the electrodes 22, 24, 26 a and 26 b are also contemplated as would occur to those of ordinary skill in the art including, for example, lamination, screen-printing, or photolithography.

In the illustrated embodiment, the electrode 22 is configured as a working electrode, the electrode 24 is configured as a reference or counter electrode, and the electrodes 26 a, 26 b are configured as sample sufficiency electrodes, with at least a portion of each of the electrodes 22, 24, 26 a and 26 b positioned within and exposed to the capillary chamber 18. Further aspects regarding the configuration and arrangement of the electrodes 22, 24, 26 a and 26 b will be set forth in greater detail below. However, it should be understood that other suitable electrode configurations and arrangements are also contemplated as falling within the scope of the present invention.

Referring specifically to FIGS. 4 and 6, the working electrode 22 includes an effective working electrode portion 70 positioned within and exposed to the capillary chamber 18, at least one lead portion 72 extending away from the effective working electrode portion 70 and positioned outside of the capillary chamber 18, and at least one contact portion 74 extending from the lead portion 72 and positioned near the proximal end 10 a of the biosensor 10. The counter electrode 24 includes an effective counter electrode portion 80 positioned within and exposed to the capillary chamber 18, at least one lead portion 82 extending from the effective counter electrode portion 80 and positioned outside of the capillary chamber 18, and at least one contact portion 84 extending from the lead portion 82 and positioned near the proximal end 10 a of the biosensor 10. Additionally, the sample sufficiency electrodes 26 a includes an effective sample sufficiency electrode portion 90 a positioned within and exposed to the capillary chamber 18, a lead portion 92 a extending from the effective sample sufficiency electrode portion 90 a and positioned outside of the capillary chamber 18, and a contact portion 94 a extending from the lead portion 92 a and positioned near the proximal end 10 a of the biosensor 10, and the sample sufficiency electrodes 26 b similarly includes an effective sample sufficiency electrode portion 90 b positioned within and exposed to the capillary chamber 18, a lead portion 92 b extending from the effective sample sufficiency electrode portion 90 b and positioned outside of the capillary chamber 18, and a contact portion 94 b extending from the lead portion 92 b and positioned near the proximal end 10 a of the biosensor 10.

In the illustrated embodiment, the leads 72, 82, 92 a, 92 b extend generally along the length/of the biosensor 10 from the effective electrode portions 70, 80, 90 a, 90 b positioned within the capillary chamber 18 to the contacts 74, 84, 94 a, 94 b, respectively. The contacts 74, 84, 94 a, 94 b provide an electrical connection with a test meter (not shown) or another device when the biosensor 10 is coupled thereto. It is contemplated that the leads 72, 82, 92 a, 92 b extending from the effective electrode portions 70, 80, 90 a, 90 b can be configured to have any suitable shape, length or configuration, and may extend to any suitable location on the support substrate 12. It is further contemplated that the number and configuration of the effective electrode portions 70, 80, 90 a, 90 b, as well as the spacing between the effective electrode portions 70, 80, 90 a, 90 b, may be varied, and that the electrode arrangement 20 may include any number of electrodes and other types/configurations of electrodes other than those specifically illustrated and described herein. For example, alternative electrode arrangements are illustrated and described in U.S. Publication No. 2011/0186428, the contents of which are hereby incorporated herein in their entirety.

Referring collectively to FIGS. 3, 5 a, 5 b and 6, in the illustrated embodiment, the spacer substrate 14 has a rectangular configuration defining a length somewhat less than the length of the support substrate 12 and the overall length 1 of the biosensor 10 so as to expose the electrode contacts 74, 84, 94 a, 94 b of the electrodes 22, 24, 26, 26 b for electrical connection with a test meter (not shown). The spacer substrate 14 also includes a bottom/lower surface or face 40, and a top/upper surface or face 42 facing a direction opposite the bottom/lower face 40. Additionally, the spacer substrate 14 includes opposite first and second end surfaces or edges 44 a, 44 b extending generally along the transverse axis T, and opposite first and second side surfaces or edges 46 a, 46 b extending generally along the longitudinal axis L and extending between the end surfaces 44 a, 44 b. While the end surfaces 44 a, 44 b and the side surfaces 46 a, 46 b of spacer substrate 14 are illustrated to form a generally rectangular shape, as indicated above, it should be understood that the biosensor 10, including the spacer substrate 14, may form other shapes and configurations without departing from the principles of the present invention.

Referring specifically to FIG. 3, the spacer substrate 14 is sized and configured to overlay the support substrate 12, with the side surfaces 46 a, 46 b of the spacer substrate 14 generally aligned with the side surfaces 36 a, 36 b of support substrate 12, and with the end surface 44 b of the spacer substrate 14 generally aligned with the end surface 34 b of support substrate 12. However, the end surface 44 a of the spacer substrate 14 is axially offset/spaced from the end surface 34 a of support substrate 12 by a distance d so as to not overlap the electrode contacts 74, 84, 94 a, 94 b on the support substrate 12 to thereby expose the electrode contacts 74, 84, 94 a, 94 b for electrical connection with a test meter (not shown).

Referring specifically to FIGS. 5a, 5b and 6, the spacer substrate 14 includes a generally rectangular-shaped notch or channel 50 extending entirely through the thickness of the spacer substrate 14 adjacent the end surface 44 b. As will be discussed in further detail below, the channel 50 forms the inner boundary of the capillary chamber 18. In the illustrated embodiment, the channel 50 is defined by an inner edge or side wall 52 facing the capillary chamber 18. In the illustrated embodiment, the inner side wall 52 extends from the end surface 44 b at a location adjacent the side surface 46 a and back to the end surface 44 b at a location adjacent the side surface 46 b to thereby provide the channel 50 with a generally rectangular-shaped configuration. Additionally, in the illustrated embodiment, the inner side wall or edge 52 includes multiple edge portions or side walls 52 a, 52 b, 52 c that extend along at least three sides of the capillary chamber 18 in a generally U-shaped pattern to define the inner outline or boundary of the capillary chamber 18, with the axial side walls 52 a, 52 b extending from the end surface 44 b and generally along the longitudinal axis L, and with the lateral side wall 52 c extending transversely between the axial side walls 52 a, 52 b. In the illustrated embodiment, the axial side walls 52 a, 52 b are interconnected with the lateral side wall 52 c via a pair of rounded corners 52 d, 52 e. The channel 50 further defines an axially-facing opening 54 adjacent the end surface 44 b, which in turn defines the sample inlet port 19 of the capillary chamber 18 adjacent the distal end 10 b of the biosensor 10. The axial side walls 52 a, 52 b are separated or offset from one another to provide the capillary chamber 18 with a capillary chamber width w_(c), and the lateral side wall 52 c is offset from the end surface 44 b to provide the capillary chamber 18 with a capillary chamber depth d_(c). Additionally, the spacer substrate 14 has a thickness measured from the bottom/lower face 40 to the top/upper face 42 to provide the capillary chamber 18 with a capillary chamber height h_(c).

Although the channel 50 has been illustrated and described as having a particular size, shape and configuration, it should be understood that other suitable sizes, shapes and configurations are also contemplated. For example, in other embodiments, the channel 50 may be provided with a non-rectangular configuration including, for example, a hemi-ovular configuration, a semi-circular configuration, a triangular configuration, or other suitable shapes and configurations. Additionally, various portions of the inner edge or side wall 52 of the channel 50 may be provided with a linear configuration, a curved or rounded configuration, a curvi-linear configuration and/or a polygonal configuration. In other embodiments, the opening 54 (and the corresponding sample inlet port 19) may be provided adjacent one of the side surfaces 46 a, 46 b of the spacer substrate 14, or adjacent the lower/bottom face 40 or the upper/top face 42 of the spacer substrate 14. Furthermore, in the illustrated embodiment, the spacer substrate 14 is configured as a single-piece, unitary spacer member. However, in other embodiments, the spacer substrate 14 can alternatively be comprised of a plurality of spacer members that are interconnected/integrated with one another to form the spacer substrate 14. In still other embodiments, the spacer substrate 14 need not necessarily include a channel 50 extending therethrough to define the inner boundary of the capillary chamber 18. For example, in other embodiments, an end surface or edge (i.e., the lateral side wall 52 c) of the spacer substrate 14 may provide a single side wall defining the inner boundary of the capillary chamber 18. In other words, the spacer substrate 14 need not necessarily include the axial side walls 52 a, 52 b or the rounded corners 52 d, 52 e, but may instead provide a single side wall (i.e., the lateral side wall 52 c) defining the inner boundary of the capillary chamber 18.

The spacer substrate 14 may formed from a wide variety of materials including an insulative material such as, for example, a flexible polymer such as an adhesive coated polyethylene terephthalate (PET)-polyester. A non-limiting example of a suitable material for the spacer substrate 14 includes a white PET film, with each of the bottom/lower and top/upper faces 40, 42 coated with a pressure-sensitive adhesive (PSA). However, it should be understood that other suitable materials and adhesives are also contemplated. It should also be understood that the bottom/lower face 40 of the spacer substrate 14 may be couple or fixed to the upper surface 32 of the support substrate 12 via the adhesive material. However, other suitable techniques/methods for coupling or fixing the spacer substrate 14 to the support substrate 12 are also contemplated including, for example, via heat or ultrasonic welding. As will be discussed in greater detail below, when the spacer substrate 14 is coupled to the support substrate 12, a portion of the top/upper surface of the support substrate 12 overlaps the capillary chamber 18 to thereby form a lower boundary of the capillary chamber 18.

When spacer substrate 14 is coupled to the support substrate 12, the effective electrode portions 70, 80, 90 a, 90 b of the electrode arrangement 20 are positioned to lie within the capillary chamber 18 which includes an inner boundary formed by the inner edge or side wall 52 of the spacer substrate 14 and the inwardly facing surfaces of the support substrate 12 and the cover substrate 16. As should be appreciated, any variation in the capillary chamber depth d_(c) defined by the position of the lateral side wall 52 c of the channel 50 relative to the end surface 44 b may introduce variation in the effective area of the effective working electrode portion 70 located within the capillary chamber 18, thereby resulting in imprecision of the measured current value related to an analyte concentration. However, as will be discussed in detail below, the biosensor 10 is designed to minimize the effects of variations in the capillary chamber depth d_(c), as well as the effective area of the effective working electrode portion 70 exposed to the capillary chamber 18 when the spacer substrate 14 is variably positioned relative to the support substrate 12.

Referring collectively to FIGS. 2, 5 a and 5 b, in the illustrated embodiment, the cover substrate 16 has a rectangular configuration defining a length generally equal to the length of the spacer substrate 14, but somewhat less than the overall length l of the biosensor 10 so as to maintain exposure of the electrode contacts 74, 84, 94 a, 94 b for electrical connection with a test meter (not shown). The cover substrate 16 includes a bottom/lower surface 60 and a top/upper surface 62 facing a direction opposite the bottom/lower surface 60 and defining an outer surface of the biosensor 10. Additionally, the cover substrate 16 includes opposite first and second end surfaces or edges 64 a, 64 b, and opposite first and second side surfaces or edges 66 a, 66 b extending generally along the longitudinal axis L and extending between the end surfaces 64 a, 64 b. While the end surfaces 64 a, 64 b and the side surfaces 66 a, 66 b of the cover substrate 16 are illustrated to form a generally rectangular shape, as indicated above, it should be understood that the biosensor 10, including the cover substrate 16, may form other shapes and configurations without departing from the principles of the present invention.

As shown in FIGS. 5a and 5b , the cover substrate 16 is sized and configured to overlay the spacer substrate 14, with the side surfaces 66 a, 66 b of the cover substrate 16 generally aligned with the side surfaces 46 a, 46 b of the spacer substrate 14, and with the end surfaces 64 a, 64 b of the cover substrate 16 generally aligned with the end surfaces 44 a, 44 b of the spacer substrate 14. The cover substrate 16 may be formed from a wide variety of materials including a flexible polymer material such as, for example, a polyester or a polyimide. One non-limiting example of a suitable polymer material is a hydrophilic polyester film. However, other suitable polymer materials or non-polymer materials are also contemplated. The bottom/lower surface 60 may be couple or fixed to the top/upper face 42 of the spacer substrate 14 via the adhesive material associated with the spacer substrate 14. However, other suitable techniques/methods for coupling or fixing the cover substrate 16 to the spacer substrate 14 are also contemplated including, for example, via heat or ultrasonic welding. When the cover substrate 16 is coupled to the spacer substrate 14, a portion of the bottom/lower surface 60 of the cover substrate 16 overlaps the capillary chamber 18 to thereby form an upper boundary of the capillary chamber 18.

Additionally, in the illustrated embodiment, the cover substrate 16 defines a series of vent holes or apertures 68 extending through the cover substrate 16 from the top/upper surface 62 to the bottom/lower surface 60 and communicating with the capillary chamber 18. In one embodiment, the vent holes 68 are arranged in a linear manner adjacent the lateral side wall 52 c of the channel 50 that forms an inner boundary of the capillary chamber 18. However, other suitable arrangements and positions of the vent holes 68 are also contemplated. As should be appreciated, the vent holes 68 serve as air outlets to vent air from the capillary chamber 18 as a fluid blood sample is drawn into the capillary chamber 18 via capillary action. Although the vent holes 68 are illustrated and described as being formed through the cover substrate 16, it should be understood that other embodiments are also contemplated where the vent holes 68 may be formed through portions of the support substrate 12 and/or the spacer substrate 14. In still other embodiments, the biosensor 10 need not necessarily include vent holes 68. For example, in alternative embodiments, other types and configurations of capillary structures as would be appreciated by those of skill in the art may be incorporated into the biosensor 10 to replace the vent holes, thereby eliminating the need for vent holes.

Referring specifically to FIGS. 5a and 5b , the capillary chamber 18 is bound/defined on the top and bottom by the bottom/lower surface 60 of the cover substrate 16 and the top/upper surface 32 of the support substrate 12, and is also bound/defined by the inner side wall 52 of the spacer substrate 14 to thereby define an inner boundary of the capillary chamber 18. The open end 54 of the channel 50 adjacent the end surfaces 44 b of the spacer substrate 14 defines the sample inlet port 19 that opens into the capillary chamber 18 to permit entry of a fluid blood sample into the capillary chamber 18. Referring to FIG. 6, the effective electrode portions 70, 80, 90 a, 90 b are positioned within and in fluid communication with the capillary chamber 18. It is further contemplated that electrochemical reagents can be positioned within the capillary chamber 18 at or near the effective electrode portions 70, 80, 90 a, 90 b. The electrochemical reagents provide electrochemical probes for specific analytes. The choice of specific reagents depends on the specific analyte or analytes to be measured, the details of which are well known to those of ordinary skill in the art and therefore need not be discussed in detail herein. An example of a reagent that may be used in association with the biosensor 10 is a reagent for measuring glucose from a whole blood sample. However, it should be understood that other suitable reagents are also contemplated for use in association with the biosensor 10.

As indicated above, the working and counter electrodes 22, 24 have effective electrode portions 70, 80, respectively, positioned within and exposed to the capillary chamber 18.

Referring to FIG. 6, shown therein is an arrangement of the effective working electrode portion 70 and the effective counter electrode portion 80 according to one embodiment of the present invention. As will be discussed in greater detail below, the arrangement and configuration of the effective working and counter electrode portions 70, 80 in combination with the configuration of other components of the biosensor 10 is designed: 1.) to maintain a balanced ratio between the effective working electrode area A_(w) and the effective counter electrode area A_(c) positioned within and exposed to the capillary chamber 18 as a result of imprecisions attributable to specification tolerances in the manufacturing of the biosensor 10; and 2.) to minimize variation in the absolute effective working electrode area A_(w) as a result of imprecisions attributable to specification tolerances in the manufacturing of the biosensor 10. Additionally, it should be understood that the electrode features/characteristics attributable to satisfying these objectives allow for the use of positive and negative pulses to enable different types of measurement methods that reduce variation in the estimated blood glucose level, further details of which will be discussed below.

In the illustrated embodiment, the effective working electrode portion 70 includes a main body portion 76 and a single neck or leg portion 78 extending therefrom, and the effective counter electrode portion 80 includes a main body or loop portion 86 and a single neck or leg portion 88 extending therefrom. In one embodiment, the main body 76 of the effective working electrode portion 70 has a generally linear configuration extending along the capillary chamber width w_(c) and arranged generally perpendicular to the longitudinal axis L of the biosensor 10, and the neck portion 78 extends from a mid-portion of the main body 76 along the capillary chamber depth d_(c) and arranged generally along the longitudinal axis L to thereby provide the effective working electrode portion 70 with a generally T-shaped configuration having a pair of generally linear portions 76 a, 76 b extending in opposite directions relative to the neck portion 78. Additionally, in one embodiment, the main body or loop portion 86 of the effective counter electrode portion 80 has a generally C-shaped or looped configuration including generally linear portions 86 a, 86 b, 86 c extending along the capillary chamber width w_(c) and arranged generally perpendicular to the longitudinal axis L of the biosensor 10, a pair of rounded or arcuate portions 86 d, 86 e interconnecting the far ends of the linear portion 86 a, 86 b with the opposite ends of the linear portion 86 c, and with the neck portion 88 extending from the near end of the linear portion 86 a along the capillary chamber depth d_(c) and arranged generally parallel with the longitudinal axis L. In the illustrated embodiment, the main body or loop 86 of the effective counter electrode portion 80 is positioned generally adjacent the main body 76 of the effective working electrode portion 70. More specifically, the main body or loop 86 of the effective counter electrode portion 80 wraps or extends peripherally about the main body 76 of the effective working electrode portion 70, with the neck portions 78, 88 arranged generally parallel with one another adjacent the longitudinal axis L and centrally positioned within the capillary chamber 18. As illustrated in FIG. 6, the corners defined by the outer edges of the effective working electrode portion 70 and the effective counter electrode portion 80 may be rounded to minimize electrical current concentrations that would otherwise be associated with sharp or non-rounded corners. As should be appreciated, such corners include those formed between the main body 76 and the neck 78, between the loop body 86 and the neck 88, and at the free ends of the main body 76 and the loop body 86. In one embodiment, the corners may be provided with a minimum radius of approximately 0.150 mm. Although specific shapes, configurations and arrangements of the effective working and counter electrode portions 70, 80 have been illustrated and described herein, it should be understood that other suitable shapes, configurations and arrangements are also contemplated as falling within the scope of the present invention.

In the illustrated embodiment, the main body 76 of the effective working electrode portion 70 has a generally uniform width w₁ along its length, and the neck 78 of the effective working electrode portion 70 has a generally uniform width w₂ along its length that is reduced/narrowed relative to the average width w₁ of the main body 76. In one embodiment, the width w₂ of the neck 78 is no more than 80% of the average width of the effective working electrode portion 70. In another embodiment, the width w₂ of the neck 78 is no more than one-half the average width of the effective working electrode portion 70. However, other ratios between the width w₂ of the working electrode neck 78 and the average width of the effective working electrode portion 70 are also contemplated. Additionally, the main body 86 of the effective counter electrode portion 80 has a generally uniform width w₃ along its length, and the neck 88 of the effective counter electrode portion 80 has a generally uniform width w₄ along its length that may be sized greater than, equal to, or less than the generally uniform width w₃ of the loop body 86. In the illustrated embodiment, the width w₂ of the working electrode neck 78 is less than the width w₄ of the counter electrode neck 88. In one embodiment, the width w₂ of the working electrode neck 78 is no more than one-half of the width w₄ of the counter electrode neck 88. In another embodiment, the width w₂ of the working electrode neck 78 is approximately 25-30% of the width w₄ of the counter electrode neck 88. However, other ratios between the width w₂ of the neck 78 and the width w₄ of the neck 88 are also contemplated. Additionally, in the illustrated embodiment, the spacing or offset distance s between the portions of the effective working electrode 70 and the adjacent portions of the effective counter electrode 80 is substantially uniform or constant along the entirety of the effective working and counter electrodes 70, 80. However, other embodiments are also contemplated where the spacing or offset distance between adjacent portions of the effective working and counter electrodes 70, 80 may vary in a non-uniform manner.

As indicated above, the effective working electrode portion 70 is provided with a single axially-extending neck 78 and the effective counter electrode portion 80 is likewise provided with a single axially-extending neck 88, with each of the necks 78, 88 extending generally parallel with one another adjacent the longitudinal axis L and centrally positioned within the capillary chamber 18. As should be appreciated, each of the necks 78, 88 extends across/intersects the inner edge or side wall 52 of the channel 50 that defines the inner boundary of the capillary chamber 18 at a single location, which in the illustrated embodiment constitutes the laterally-extending side wall 52 c. As should also be appreciated, the axial location of the laterally-extending side wall 52 c relative to the effective working and counter electrode portions 70, 80 may vary as a result of imprecisions attributable to tolerance specifications associated with the manufacturing process of the biosensor 10. Such imprecisions include but are not limited to variable axial placement of the spacer substrate 14 relative to the support substrate 12 (and the effective working and counter electrode portions 70, 80) along the longitudinal axis L, variations in the placement/size of the lateral side wall 52 c of the spacer substrate 14, variations in the placement of the effective working and counter electrode portions 70, 80 on the support substrate 12, and/or other variations associated with the manufacturing and assembly of the biosensor 10. However, the manufacturing specifications associated with the biosensor 10 are determined to dictate/ensure that the sole portions of the effective working and counter electrode portions 70, 80 that extend across/intersect the laterally-extending side wall 52 c (or any portion of the inner wall 52) of the capillary chamber 18 are the working and counter electrode necks 78, 88. In other words, the manufacturing specifications dictate/ensure that the laterally-extending side wall 52 c (or any other portion of the inner side wall 52) does not intersect/overlap/cover any portion of the main bodies 76, 86 of the effective electrode portions 70, 80, thereby ensuring that the main bodies 76, 86 of the effective electrode portions 70, 80 are positioned entirely within the capillary chamber 18 and are not covered by any portion of the spacer substrate 14.

Referring to FIGS. 7a-7c , shown therein are three exemplary axial placements of the spacer substrate 14 relative to the support substrate 12 (and the capillary portions of the working and counter electrodes 22, 24 positioned in the capillary chamber 18) that may result from imprecisions associated with the manufacturing and assembly process of the biosensor 10. Specifically, FIG. 7a illustrates a nominal placement of the spacer substrate 14 relative to the support substrate 12 and the electrode arrangement 20 (i.e., the optimal specification tolerance limit on placement of the spacer substrate 14). In this nominal placement of the spacer substrate 12, each of the necks 78, 88 of the working and counter capillary electrodes 22, 24 extend across/intersect the inner boundary of the capillary chamber 18 at a single location (i.e., at the laterally-extending side wall 52 c), and the main electrode bodies 76, 86 are positioned entirely within the capillary chamber 18 with the laterally-extending side wall 52 c of the capillary chamber 18 spaced from the linear portions 86 a, 86 b of the effective counter electrode portion 80 at a nominal distance d_(nom). FIG. 7b illustrates a maximal placement of the spacer substrate 14 relative to the support substrate 12 and the electrode arrangement 20 (i.e., the upper specification tolerance limit on placement of the spacer substrate 14). In this maximal placement of the spacer substrate 12, the electrode necks 78, 88 still extend across/intersect the inner boundary of the capillary chamber 18 at a single location, and the main electrode bodies 76, 86 are still positioned entirely within the capillary chamber 18, but the laterally-extending side wall 52 c of the capillary chamber 18 is spaced from the linear portions 86 a, 86 b of the effective counter electrode portion 80 at a maximum distance d_(max). FIG. 7c illustrates a minimal placement of the spacer substrate 14 relative to the support substrate 12 and the electrode arrangement 20 (i.e., the lower specification tolerance limit on placement of the spacer substrate 14). In this minimal placement of the spacer substrate 12, the electrode necks 78, 88 still extend across/intersect the inner boundary of the capillary chamber 18 at a single location, and the main electrode bodies 76, 86 are still positioned entirely within the capillary chamber 18, but the laterally-extending side wall 52 c of the capillary chamber 18 is spaced from the main electrode bodies 76, 86 at a minimum distance d_(min), which in the illustrated embodiment constitutes a substantially flush arrangement of the laterally-extending side wall 52 c relative to the linear portions 86 a, 86 b of the effective counter electrode portion 80.

As should be appreciated, since the area of the effective working electrode portion 70 certain to be positioned within the capillary chamber 18 is significantly greater than the potential variance in the area of the neck 78 positioned within the capillary chamber 18 resulting from acceptable tolerance levels associated with imprecisions in the manufacturing process, variations in the effective working electrode area A_(w) of the effective working electrode portion 70 exposed to the capillary chamber 18 is minimized, thereby resulting in improved measurement precision and/or accuracy of the biosensor 10. This minimization of the variation in the effective working electrode area A_(w) is primarily attributable to the reduced/narrowed width w₂ of the neck 78 relative to the average width of the effective electrode portion 70 (i.e., minimization of the change in the area of the neck 78 along the reduced/narrowed width w₂ per unit length of the neck 78), and the assurance that the sole portion of the effective working electrode portion that extends across/intersects the inner boundary of capillary chamber 18 (i.e., the inner side wall 52) is the reduced/narrowed width w₂ of the single neck 78 that extends across/intersects the laterally-extending side wall 52 c.

As should also be appreciated, since the effective working and counter electrode areas (A_(w), A_(c)) of the effective working and counter electrode portions 70, 80 certain to be positioned within the capillary chamber 18 is significantly greater than the potential variance in the areas of the necks 78, 88 positioned within the capillary chamber 18 resulting from acceptable tolerance levels associated with imprecisions in the manufacturing process of the biosensor 10, a relatively constant/uniform ratio R between the effective counter electrode area A_(c) and the effective working electrode area A_(w) exposed to the capillary chamber 18 can be maintained, which likewise results in improved measurement precision and/or accuracy of the biosensor 10.

The general meaning of the term “relatively constant” (when used in association with ratio R) is that for given uses of biosensors embodying the present invention, maintaining ratio R as uniform or otherwise absolutely constant is not necessary in contexts in which a certain amount of tolerance is acceptable. For example, in the context of the biosensor 10 illustrated in FIGS. 7a-7c , if the minimal spacer position is adjusted such that the inner boundary of the capillary chamber overlaps the electrode necks 78, 88 at a portion where one or both of the necks 78, 88 begin to radius outwardly to the main body 76, 86 of each electrode, respectively, then ratio R cannot be maintained uniformly. Nevertheless, the difference between ratio R at the nominal and maximal spacer positions and the ratio R at the minimal spacer position is relatively constant, and may still be acceptable depending on the degree of accuracy required for the particular use of the biosensor 10.

In order to maintain a relatively constant/uniform ratio R between the effective counter electrode area A_(c) and the effective working electrode area A_(w) (i.e., R=A_(c)/A_(w)) in view of the acceptable tolerance levels associated with the manufacturing process of the biosensor 10, the following formula may be applied to provide parameters regarding the configuration/design of the working and counter electrodes: A_(c)/w₄=A_(w)/w₂ (where A_(c) is the effective counter electrode area, w₄ is the width of the counter electrode neck 88, A_(w) is the effective working electrode area, and w₂ is the width of the working electrode neck 78).

It should be understood that the effective working electrode area A_(w) and the effective counter electrode area A_(c) are defined as the respective areas of the effective working and counter electrode portions 70, 80 exposed to the capillary chamber 18 and in contact with a fluid blood sample in the capillary chamber 18 when the capillary chamber 18 contains a sufficient volume of the fluid blood sample to initiate a measurement sequence. It should also be understood that the widths w₂, w₄ of the working and counter electrode necks 78, 88 are defined as the widths of the necks 78, 88 that are intersected/overlapped by inner boundary of the capillary chamber 18 (i.e., the laterally-extending side wall 52 c).

In the illustrated embodiment, the sample sufficiency electrodes 26 a, 26 b are configured as working and counter sample sufficiency electrodes, and are configured as substantially mirror images of one another relative to the longitudinal axis L. However, it should be understood that other embodiments are also contemplated wherein the sample sufficiency electrodes 26 a, 26 b are provided with different configurations. In still other embodiments, the sample sufficiency electrodes 26 a, 26 b are optional and are not included in the biosensor 10. In one embodiment, the sample sufficiency electrodes 26 a comprises a working sample sufficiency electrode, and the sample sufficiency electrodes 26 b comprises a counter sample sufficiency electrode. However, a reverse configuration is also contemplated. As shown in the FIG. 6, the effective sample sufficiency electrode portions 90 a, 90 b of the sample sufficiency electrodes 26 a, 26 b each have a generally triangular-shaped cross section that extends into the capillary chamber 18 from opposite sides of the capillary chamber 18. In the illustrated embodiment, the triangular-shaped effective electrode portions 90 a, 90 b each have a side surface 96 a arranged at an obtuse angle relative to the longitudinal axis L, and an end surface 96 b extending from the side surface 96 a and arranged generally perpendicular to the longitudinal axis L. However, other suitable shapes and configurations of the capillary electrode portions 90 a, 90 b are also contemplated. As set forth herein, the sample sufficiency electrodes 26 a, 26 b are configured to detect when a sufficient volume of a liquid blood sample is received within the capillary chamber 18.

In use, a number of the biosensors 10 are typically packaged in a vial that usually includes a stopper or cap configured to seal the vial. It should be appreciated, however, that the biosensors may be packaged individually, or biosensors 10 can be folded upon one another, rolled in a coil, stacked in a cassette magazine, or packed in blister packaging. In another embodiment, the packaging may be formed as a card with removable individual segments comprised of biosensors, examples of which may be found in U.S. patent application Ser. No. 12/198,197, the contents of which are incorporated herein by reference in their entirety.

Many fluid sample types may be analyzed using the biosensor 10 discussed herein. For example, human body fluids such as, for example, whole blood, plasma, sera, lymph, bile, urine, semen, cerebrospinal fluid, spinal fluid, lacrimal fluid and stool specimens as well as other biological fluids readily apparent to one skilled in the art may be measured. Fluid preparations of tissues can also be assayed, along with foods, fermentation products and environmental substances, which potentially contain environmental contaminants. Whole blood may be assayed with the biosensor 10.

A user of the biosensor 10 initially places a finger having a blood collection incision or puncture adjacent/against the sample inlet port 19 to the capillary chamber 18. Capillary forces pull a liquid blood sample from the incision or puncture through the sample inlet port 19 and into the capillary chamber 18 and across the reagents and the electrode arrangement 20 located in the capillary chamber 18. The liquid blood sample dissolves the reagents and engages the electrode arrangement 20 in the capillary chamber 18 where an electrochemical reaction takes place. In embodiments of the biosensor 10 including the sample sufficiency electrodes 26 a, 26 b, a signal is generated when the liquid blood sample in the capillary chamber 18 contacts the effective electrode portions 90 a, 90 b, thereby indicating that a sufficient volume of the liquid blood sample has been received in the capillary chamber 18. Sometime after the reaction has begun, a power source (e.g., a battery) applies a potential difference between the working and counter electrodes 22, 24. When the potential difference is applied, the amount of oxidized form of the mediator at the counter electrode 24 and the potential difference must be sufficient to cause electro-oxidation of the reduced form of the mediator at the surface of the working electrode 22. A current measuring meter (not shown) measures the current generated by the oxidation of the reduced form of the mediator at the surface of the working electrode 22.

As indicated above, the biosensor 10 disclosed herein is configured to minimize variations in the effective working electrode area A_(w) exposed to the capillary chamber 18, and also maintains a relatively constant/uniform ratio R between the effective counter electrode area A_(c) and the effective working electrode area A_(w) exposed to the capillary chamber 18, thereby resulting in improvements to the precision and/or accuracy of the biosensor 10, and more particularly to improved precision and/or accuracy of measured blood glucose levels. It should be appreciated that such improvements to the precision and/or accuracy of the biosensor 10 resulting from the unique configuration and features associated with the working and counter electrodes 22, 24 and other structures/features associated with the biosensor 10 are particularly apparent in biosensor applications involving the use of both positive and negative pulsed signals between the working and counter electrodes 22, 24 in the sensing/measurement process to enable ascorbate detection and measurement of blood glucose levels. Such positive/negative pulsed signals may be realized via the positive/negative pulses inherent in AC signals, and/or positive/negative pulses that may stem from the use of varied DC signals exhibiting positive and negative polarity. However, it should be understood that in other embodiments, the biosensor 10 need not necessarily be used in applications involving pulsed signals.

Referring to FIGS. 8a-8c , illustrated therein is a first comparative biosensor 100 including many of the same elements and features illustrated and described above with regard to the biosensor 10. For example, the comparative biosensor 100 has a proximal end (not shown) and an opposite distal end 100 b arranged along a longitudinal axis L, and generally includes an electrode support substrate 112, an intermediate spacer substrate 114 positioned on the support substrate 112, and a cover substrate or hydrophilic roof (not shown) positioned on the spacer substrate 114. The support substrate 112, the spacer substrate 114 and the cover substrate cooperate with one another to define a capillary chamber or channel 118 having a sample inlet port for receiving a fluid sample adjacent the distal end 100 b of the biosensor 100. Additionally, the support substrate 112 includes an electrical conductor arrangement 120 including a series of electrodes 122, 124, 126 a and 126 b that each include one or more electrode portions positioned within the capillary chamber 118. In the illustrated embodiment, the electrode 122 is configured as a working electrode, the electrode 124 is configured as a reference or counter electrode, and the electrodes 126 a, 126 b are configured as sample sufficiency electrodes.

In the illustrated embodiment, the working electrode 122 includes an effective working electrode portion exposed to the capillary chamber 118 having a main body portion 176 and a single neck or leg portion 178 extending therefrom to thereby define a generally T-shaped configuration, and the counter electrode 124 includes an effective counter electrode portion having a main body or loop portion 186 positioned generally adjacent the main body 176 of the effective working electrode portion, and more specifically defining a generally C-shaped or looped configuration that wraps or extends peripherally about the main body 176 of the effective working electrode portion and also having a single neck or leg portion 188 extending from the main body 186. However, unlike the biosensor 10 illustrated and described above, the body portion 176 and the neck portion 178 of the working electrode 122 have a substantially equal/uniform electrode width (i.e., the width of the neck 178 is not reduced relative to the main body 176). Additionally, the neck portion 178 of the working electrode 122 has a width that is substantially equal to the width of the neck portion 188 of the counter electrode 124. It should be appreciated that other than the increased width of the working electrode neck 178, the biosensor 100 is configured substantially identical to the biosensor illustrated and described above.

FIGS. 8a-8c illustrate three exemplary axial placements of the spacer substrate 114 relative to the support substrate 112 (and relative to the effective portions of the working and counter electrodes 122, 124 positioned in the capillary chamber 118) that may result from imprecisions associated with the manufacturing and assembly process of the biosensor 100. It should be appreciated that the exemplary axial placements of the spacer substrate 114 relative to the support substrate 112 illustrated in FIGS. 8a-8c correspond to the exemplary axial placements of the spacer substrate 14 relative to the support substrate 12 illustrated and described above with regard to FIGS. 7a -7 c.

Referring specifically to FIG. 8a , illustrated therein is a nominal placement of the spacer substrate 114 relative to the support substrate 112 and the electrode arrangement 120. In this nominal placement, the necks 178, 188 of the working and counter capillary electrodes 122, 124 extend across/intersect the inner boundary of the capillary chamber 118 at a single location (i.e., at the laterally-extending side wall 152 c), and the main electrode bodies 176, 186 are positioned entirely within the capillary chamber 118 with the laterally-extending side wall 152 c of the capillary chamber 118 spaced from the linear portions 186 a, 186 b of the effective counter electrode portion at a nominal distance d_(nom). FIG. 8b illustrates a maximal placement of the spacer substrate 114 relative to the support substrate 112 and the electrode arrangement 120 wherein the electrode necks 178, 188 extend across/intersect the inner boundary of the capillary chamber 118 at a single location, and the main electrode bodies 176, 186 are positioned entirely within the capillary chamber 18, but the laterally-extending side wall 152 c of the capillary chamber 118 is spaced from the linear portions 186 a, 186 b of the effective counter electrode portion at a maximum distance d_(max). FIG. 8c illustrates a minimal placement of the spacer substrate 114 relative to the support substrate 112 and the electrode arrangement 120 wherein the electrode necks 178, 188 extend across/intersect the inner boundary of the capillary chamber 118 at a single location, and the main electrode bodies 176, 186 are positioned entirely within the capillary chamber 118, but the laterally-extending side wall 152 c of the capillary chamber 118 is spaced from the main electrode bodies 176, 186 at a minimum distance d_(min), which in the illustrated embodiment constitutes a substantially flush arrangement of the laterally-extending side wall 152 c relative to the linear portions 186 a, 186 b of the effective counter electrode portion.

Referring to FIGS. 9a-9c , illustrated therein is a second comparative biosensor 200 including some of the same elements and features illustrated and described above with regard to the biosensor 10, but having a different configuration and layout relative to the biosensor 10. In the illustrated embodiment, the comparative biosensor 200 has a proximal end (not shown) and an opposite distal end 200 b arranged along a longitudinal axis L, and generally includes an electrode support substrate 212 and an intermediate spacer substrate 214 positioned on the support substrate 212. The comparative biosensor 200 may further include a cover substrate or hydrophilic roof (not shown) positioned on the spacer substrate 214. The support substrate 212, the spacer substrate 214 and the cover substrate cooperate with one another to define a capillary chamber or channel 218 having a sample inlet port for receiving a fluid sample adjacent the distal end 200 b of the biosensor 200. Additionally, the support substrate 212 includes an electrical conductor arrangement 220 including a series of electrodes 222, 224, 226 a and 226 b that each include one or more electrode portions positioned within the capillary chamber 218. In the illustrated embodiment, the electrode 222 is configured as a working electrode, the electrode 224 is configured as a reference or counter electrode, and the electrodes 226 a, 226 b are configured as sample sufficiency electrodes.

Unlike the biosensor 10 which includes a capillary chamber 18 having a generally U-shaped configuration (i.e., bound by a pair of axial side walls 52 a, 52 b and a lateral side wall 52 c which together define the inner boundary of the capillary chamber 18), the capillary chamber 218 of the biosensor 200 extends across the entire width of the support substrate 212. In this embodiment, the distal edge of the spacer substrate 214 provides a laterally-extending side wall 252 c defining an inner boundary of the capillary chamber 218. However, other configurations are also possible, including embodiments similar to the biosensor 10 where the capillary chamber defines a generally U-shaped configuration.

In the illustrated embodiment, the working electrode 222 includes an effective working electrode portion exposed to the capillary chamber 218 and having a main body portion 276 and a single neck or leg portion 278 extending from an end of the main body portion 276 to thereby define a generally L-shaped electrode configuration. Like the biosensor 10 illustrated and described above, the effective working electrode portion includes a single neck portion that extends across/intersect the inner boundary of the capillary chamber 218 at a single location (i.e., at the laterally-extending side wall 252 c). Additionally, in the illustrated embodiment, the counter electrode 224 includes an effective counter electrode portion exposed to the capillary chamber 218 and having a first arm portion 286 defining a generally U-shaped configuration that extends or wraps about a distal side of the main body portion 276 of the effective working electrode portion, and a second arm portion 288 defining a generally linear configuration extending along a proximal side of the main body portion 276 and arranged generally parallel with the main body portion 276. More specifically, the first arm portion 286 and the second arm portion 288 together provide the effective counter electrode portion with a looped configuration that wraps or extends peripherally about and encloses the main body portion 276 and the neck portion 278 of the effective working electrode. However, unlike the biosensor 10 illustrated and described above, the effective counter electrode does not include a single neck portion that extends across/intersect the inner boundary of the capillary chamber 218 at a single location (i.e., at the laterally-extending side wall 252 c). Instead, the end of the first arm portion 286 and the entire length of the second arm portion 288 extend across/intersect the inner boundary of the capillary chamber 218 at the laterally-extending side wall 252 c.

FIGS. 9a-9c illustrate three exemplary axial placements of the spacer substrate 214 relative to the support substrate 212 (and relative to the effective portions of the working and counter electrodes 222, 224 positioned in the capillary chamber 218) that may result from imprecisions associated with the manufacturing and assembly process of the biosensor 200. It should be appreciated that the exemplary axial placements of the spacer substrate 214 relative to the support substrate 212 illustrated in FIGS. 9a-9c correspond to the exemplary axial placements of the spacer substrate 14 relative to the support substrate 12 illustrated and described above with regard to FIGS. 7a -7 c.

Referring specifically to FIG. 9a , illustrated therein is a nominal placement of the spacer substrate 214 relative to the support substrate 212 and the electrode arrangement 220. In this nominal placement, the neck 278 of the working electrode 222 extends across/intersects the inner boundary of the capillary chamber 218 at a single location (i.e., at the laterally-extending side wall 252 c). However, the counter electrode 224 extends across/intersects the inner boundary of the capillary chamber 218 at multiple locations. More specifically, the first and second arm portions 286, 288 of the counter electrode 224 each extend across/intersect the inner boundary of the capillary chamber 218 at the laterally-extending side wall 252 c. Additionally, while the main body portion 276 of the working electrode 222 is positioned entirely within the capillary chamber 218, portions of the first and second arm portions 286, 288 of the counter electrode 224 extend outside of the capillary chamber 218.

As illustrated in FIG. 9a , nominal placement of the spacer substrate 214 relative to the support substrate 212 results in the laterally-extending side wall 252 c of the capillary chamber 218 (i.e., the distal edge of the spacer substrate 214) being spaced from the distal side 288 b of the second arm portion 288 of the counter electrode 224 at a nominal distance d_(nom). As illustrated in FIG. 9b , maximal placement of the spacer substrate 214 relative to the support substrate 212 results in the laterally-extending side wall 252 c of the capillary chamber 218 (i.e., the distal edge of the spacer substrate 214) being spaced from the distal side 288 b of the second arm portion 288 at a maximum distance d_(max), which in the illustrated embodiment constitutes a substantially flush arrangement of the laterally-extending side wall 252 c relative to the proximal side 288 a of the second arm portion 288 of the counter electrode 224. As illustrated in FIG. 9c , minimal placement of the spacer substrate 214 relative to the support substrate 212 results in the laterally-extending side wall 252 c of the capillary chamber 218 (i.e., the distal edge of the spacer substrate 214) being spaced from the distal side 288 b of the second arm portion 288 at a minimum distance d_(min), which in the illustrated embodiment constitutes a substantially flush arrangement of the laterally-extending side wall 252 c relative to the distal side 288 b of the second arm portion 288 of the counter electrode 224.

For purposes of comparing the features, attributes and characteristics associated with the biosensor 10 relative to the comparative biosensors 100 and 200, Table A sets forth data associated with the biosensor 10 in the three exemplary configurations illustrated in FIGS. 7a-7c (i.e., the nominal, maximum, minimum positions of the spacer substrate 14), Table B sets forth data associated with the comparative biosensor 100 in the three exemplary configurations illustrated in FIGS. 8a-8c (i.e., the nominal, maximum, minimum positions of the spacer substrate 114), and Table C sets forth data associated with the comparative biosensor 200 in the three exemplary configurations illustrated in FIGS. 9a-9c (i.e., the nominal, maximum, minimum positions of the spacer substrate 214). It should be understood that the data set forth in Tables A, B and C is exemplary in nature, and does not in any way limit the scope of the present invention.

Referring to Table A below in combination with FIGS. 7a-7c , as indicated above, the biosensor 10 is designed and configured to minimize variations in the effective working electrode area A_(w) of the working electrode 22 exposed to the capillary chamber 18 in view of acceptable tolerance levels associated with manufacturing of the biosensor 10. Additionally, the biosensor 10 is also designed and configured to maintain a relatively constant/uniform ratio R between the effective counter electrode area A_(c) of the counter electrode 24 exposed to the capillary chamber 18 and the effective working electrode area A_(w) of the working electrode 22 exposed to the capillary chamber 18 (i.e., R=A_(c)/A_(w)) in view of the acceptable tolerance levels associated with manufacturing of the biosensor 10.

TABLE A % % Variation Effective Effective Variation of Counter Working of WE Area Area Electrode Electrode Area A_(W) Ratio Ratio Area A_(C) Area A_(W) (from R = R (from (mm²) (mm²) nominal) A_(C)/A_(W) nominal) Nominal Spacer 0.68099 0.31751 — 2.145 — Position (d_(nom)) Maximum Spacer 0.69865 0.32576 +2.60% 2.145 0.00% Position (d_(max)) Minimum Spacer 0.66332 0.30926 −2.60% 2.145 0.00% Position (d_(min))

With regard to minimizing variations in the effective working electrode area A_(w) of the working electrode 22, the biosensor 10 is designed and configured to minimize such variations as the position/placement of the inner boundary of the capillary chamber 18 (i.e., the inner side wall 52 c) is varied between the nominal tolerance position illustrated in FIG. 7a and the maximum and minimum tolerance positions illustrated in FIGS. 7b and 7c , respectively. As indicated above, since the effective working electrode area A_(w) positioned within the capillary chamber 18 is significantly greater than the variance in the area of the neck 78 positioned within the capillary chamber 18 as the position of the inner boundary of the capillary chamber 18 is varied between the nominal, maximum and minimum tolerance positions, variance in the effective working electrode area A_(w) is minimized. This minimization in the variation of the effective working electrode area A_(w) is at least partially attributable to the reduced/narrowed width of the neck 78 relative to the width of the main body 76 of the effective working electrode (i.e., minimization of the change in the area of the neck 78 per unit length of the neck 78), as well as limiting the portion of the working electrode 22 that intersects the variable inner boundary (i.e., the inner side wall 52 c) of the capillary chamber 18 to the reduced/narrowed width of the working electrode neck 78.

As illustrated in Table A, in the exemplary embodiment of the biosensor 10, the variation of the effective working electrode area A_(w) between the nominal and the maximum spacer positions is +2.60%, and the variation of the effective working electrode area A_(w) between the nominal and the minimum spacer positions is −2.60%. Additionally, the overall variation of the effective working electrode area A_(w) between the maximum and minimum spacer positions is +5.07%. In this exemplary embodiment, the width of the working electrode neck 78 is 0.050 mm, the width of the counter electrode neck 88 is 0.107 mm, the width of the working electrode main body 76 is 0.100 mm, and the width of the counter electrode main body 86 is 0.100 mm. Additionally, the nominal distance d_(nom) is 1.000 mm, the maximum distance d_(max) is 1.165 mm, and the minimum distance d_(min) is 0.835 mm. However, it should be understood that these values are exemplary in nature and do not in any way limit the scope of the present invention. As should be appreciated, minimizing variations in the effective working electrode area A_(w) as the position/placement of the inner boundary of the capillary chamber 18 is varied due to tolerance levels associated with manufacturing of the biosensor 10 results in perceptible improvements in the precision and/or accuracy of the biosensor 10, which in turn results in improved precision and/or accuracy of measured blood glucose levels.

With regard to maintaining a relatively constant/uniform ratio R between the effective counter electrode area A_(c) of the counter electrode 24 and the effective working electrode area A_(w) of the working electrode 22, the biosensor 10 is designed and configured to substantially maintain the area ratio R as the position/placement of the inner boundary of the capillary chamber 18 (i.e., the inner side wall 52 c) is varied between the nominal tolerance position illustrated in FIG. 7a and the maximum and minimum tolerance positions illustrated in FIGS. 7b and 7c , respectively. As indicated above, the biosensor 10 and the size/shape/configuration of the effective portions of the working and counter electrodes 22, 24 are specifically designed such that the ratio R between the effective electrode areas A_(c), A_(w) is substantially maintained as the position of the inner boundary of the capillary chamber 18 is varied between the nominal, maximum and minimum tolerance positions. Maintaining a relatively constant/uniform ratio R is at least partially attributable to the reduced/narrowed width of the working electrode neck 78 relative to the width of the counter electrode neck 88, the reduced effective working electrode areas A_(w) relative to the effective counter electrode areas A_(c), as well as limiting the portions of the working and counter electrodes 22, 24 that intersects the variable inner boundary of the capillary chamber 18 to the working and counter electrode necks 78, 88.

As illustrated in Table A, in one embodiment, the variation in the area ratio R (i.e., A_(c)/A_(w)) between the nominal and the maximum spacer positions is 0.00%, and the variation in the area ratio R between the nominal and the minimum spacer positions is also 0.00%. Additionally, the overall variation in the area ratio R between the maximum and minimum spacer positions is likewise 0.00%. As discussed above, maintaining a relatively constant/uniform ratio R between the effective counter electrode area A_(c) and the effective working electrode area A_(w) as the position/placement of the inner boundary of the capillary chamber 18 is varied due to tolerance levels associated with manufacturing of the biosensor 10 results in perceptible improvements in the precision and/or accuracy of the biosensor 10, which in turn results in improved precision and/or accuracy of measured blood glucose levels. As should be appreciated, the illustrated embodiment of the biosensor 10 exhibits a perfectly constant/uniform ratio R between the effective counter electrode area A_(c) and the effective working electrode area A_(w) as the position/placement of the inner boundary of the capillary chamber 18 is varied due to tolerance levels associated with manufacturing of the biosensor 10. However, it should be appreciated that other embodiments of the biosensor 10 are also contemplated where the biosensor exhibits a relatively constant/uniform ratio R between the effective counter electrode area A_(c) and the effective working electrode area A_(w).

Referring to Table B below in combination with FIGS. 8a-8c , shown therein is data associated with the comparative biosensor 100. As indicated above, the comparative biosensor 100 is in many respects configured similar to the biosensor 10. However, the neck portion 178 of the working electrode 122 has a width that is equal to or greater than the width of the body portion 176 (i.e., the width of the neck 178 is not reduced relative to the width of the main body 176). Additionally, the neck portion 178 of the working electrode 122 has a width that is substantially equal to the width of the neck portion 188 of the counter electrode 124.

As will become apparent below, compared to the biosensor 10, the particular configuration of the working electrode 122 of the comparative biosensor 100 is not specifically designed to minimize variations in the effective working electrode area A_(w) as the position/placement of the inner boundary of the capillary chamber 118 is varied between the tolerance positions illustrated in FIGS. 8a-8c . Additionally, compared to the biosensor 10, the particular configuration of the working and counter electrodes 122, 124 of the comparative biosensor 100 are not specifically designed to maintain a relatively constant/uniform ratio R between the effective counter electrode area A_(c) and the effective working electrode area A_(w) as the position/placement of the inner boundary of the capillary chamber 118 is varied between the tolerance positions illustrated in FIGS. 8a-8c .

TABLE B % % Variation Effective Effective Variation of Counter Working of WE Area Area Electrode Electrode Area A_(W) Ratio Ratio Area A_(C) Area A_(W) (from R = R (from (mm²) (mm²) nominal) A_(C)/A_(W) nominal) Nominal Spacer 0.67459 0.33751 — 1.999 — Position (d_(nom)) Maximum Spacer 0.69109 0.35401 +4.89% 1.952 −2.35% Position (d_(max)) Minimum Spacer 0.65808 0.32101 −4.89% 2.050 +2.55% Position (d_(min))

As illustrated in Table B, in the exemplary embodiment of the biosensor 100, the variation of the effective working electrode area A_(w) between the nominal and the maximum spacer positions is +4.89%, and the variation of the effective working electrode area A_(w) between the nominal and the minimum spacer positions is −4.89%. Additionally, the overall variation of the effective working electrode area A_(w) between the maximum and minimum spacer positions is −9.32%. In this exemplary embodiment, the width of the working electrode neck 178 is 0.100 mm, the width of the counter electrode neck 188 is 0.100 mm, the width of the working electrode main body 176 is 0.100 mm, and the width of the counter electrode main body 186 is 0.100 mm. Additionally, the nominal distance d_(nom) is 1.000 mm, the maximum distance d_(max) is 1.165 mm, and the minimum distance d_(min) is 0.835 mm. As should be appreciated, due to the increased width of the working electrode neck 178 (relative to the reduced width of the working electrode neck 78), the comparative biosensor 100 exhibits greater variations in the effective working electrode area A_(w) compared to the biosensor 10 as the position/placement of the inner boundary of the capillary chamber is varied due to tolerance levels associated with manufacturing of the biosensor. Accordingly, the comparative biosensor 100 does not exhibit the same improvements in precision and/or accuracy as exhibited by the biosensor 10.

Additionally, the comparative biosensor 100 likewise does not maintain as constant/uniform of a ratio R between the effective counter electrode area A_(c) and the effective working electrode area A_(w) compared to the biosensor 10 as the position/placement of the inner boundary of the capillary chamber is varied due to tolerance levels associated with manufacturing of the biosensor. Specifically, as illustrated in Table B, the variation in the area ratio R (i.e., A_(c)/A_(w)) between the nominal and the maximum spacer positions is −2.35%, and the variation in the area ratio R between the nominal and the minimum spacer positions is +2.55%. Additionally, the overall variation in the area ratio R between the maximum and minimum spacer positions is +5.02%. As should be appreciated, the comparative biosensor 100 exhibits greater variations in the area ratio R between the effective electrode areas A_(c), A_(w) compared to the biosensor 10 as the position/placement of the inner boundary of the capillary chamber is varied due to tolerance levels associated with manufacturing of the biosensor. Accordingly, it should be appreciated that the comparative biosensor 100 does not exhibit the same improvements in precision and/or accuracy as the biosensor 10.

Referring to Table C below in combination with FIGS. 9a-9c , shown therein is data associated with the comparative biosensor 200. As indicated above, the comparative biosensor 200 is in some respects configured similar to the biosensor 10. However, the neck portion 278 of the working electrode 222 has a width that is equal to or greater than the width of the body portion 276 (i.e., the width of the neck 278 is not reduced relative to the width of the main body 276). Additionally, the neck portion 278 of the working electrode 222 has a width that is substantially equal to the width of the first arm portion 286 of the counter electrode 224. Additionally, as indicated above, unlike the biosensor 10, the effective counter electrode portion of the counter electrode 224 does not include a single “neck” that extends across/intersects the inner boundary of the capillary chamber 218 at a single location (i.e., at the laterally-extending side wall 252 c). Instead, the end of the first arm portion 286 and the entire length of the second arm portion 288 each extend across/intersect the inner boundary of the capillary chamber 218 at the laterally-extending side wall 252 c.

As will become apparent below, compared to the biosensor 10, the particular configuration of the working electrode 222 and the counter electrode 224 of the comparative biosensor 200 are not specifically designed to minimize variations in the effective working electrode area A_(w) and in the effective counter electrode area A_(c) as the position/placement of the inner boundary of the capillary chamber 218 is varied between the tolerance positions illustrated in FIGS. 9a-9c . Additionally, compared to the biosensor 10, the particular configuration of the working and counter electrodes 222, 224 of the comparative biosensor 200 are not specifically designed to maintain a relatively constant/uniform ratio R between the effective counter electrode area A_(c) and the effective working electrode area A_(w) as the position/placement of the inner boundary of the capillary chamber 218 is varied between the tolerance positions illustrated in FIGS. 9a-9c .

TABLE C % % Variation Effective Effective Variation of Counter Working of WE Area Area Electrode Electrode Area A_(W) Ratio Ratio Area A_(C) Area A_(W) (from R = R (from (mm²) (mm²) nominal) A_(C)/A_(W) nominal) Nominal Spacer 1.08544 0.45493 — 2.386 — Position (d_(nom)) Maximum Spacer 1.49299 0.47143 +3.63 3.167 +32.73 Position (d_(max)) Minimum Spacer 0.67789 0.43843 −3.63 1.546 −35.21 Position (d_(min))

As illustrated in Table C, in the exemplary embodiment of the biosensor 200, the variation of the effective working electrode area A_(w) between the nominal and the maximum spacer positions is +3.63%, and the variation of the effective working electrode area A_(w) between the nominal and the minimum spacer positions is −3.63%. Additionally, the overall variation of the effective working electrode area A_(w) between the maximum and minimum spacer positions is −7.00%. In this exemplary embodiment, the width of the working electrode neck 278 is 0.100 mm, the width of the working electrode main body 276 is 0.100 mm, the width of the counter electrode first arm portion 286 is 0.100 mm, and the width of the counter electrode second arm portion 288 is significantly greater than 0.100 mm. Additionally, the nominal distance d_(nom) can be 1.000 mm, the maximum distance d_(max) can be 1.165 mm, and the minimum distance d_(min) can be 0.835 mm. As should be appreciated, the effective counter electrode portion of the counter electrode 224 does not include a “neck” extending across/intersecting the inner boundary of the capillary chamber 218, as that term is typically referred to by those having ordinary skill in the art. Instead, the end of the first arm portion 286 and the entire length of the second arm portion 288 each extend across/intersect the inner boundary of the capillary chamber 218 at the laterally-extending side wall 252 c.

As should also be appreciated, due to the increased width of the working electrode neck 278 (relative to the reduced width of the working electrode neck 78), the comparative biosensor 200 exhibits greater variations in the effective working electrode area A_(w) compared to the biosensor 10 as the position/placement of the inner boundary of the capillary chamber is varied due to tolerance levels associated with manufacturing of the biosensor. Accordingly, the comparative biosensor 200 does not exhibit the same improvements in precision and/or accuracy as exhibited by the biosensor 10. As should be further appreciated, the comparative biosensor 200 likewise does not maintain as constant/uniform of a ratio R between the effective counter electrode area A_(c) and the effective working electrode area A_(w) compared to the biosensor 10 as the position/placement of the inner boundary of the capillary chamber is varied due to tolerance levels associated with manufacturing of the biosensor. Specifically, as illustrated in Table C, the variation in the area ratio R (i.e., A_(c)/A_(w)) between the nominal and the maximum spacer positions is +32.73, and the variation in the area ratio R between the nominal and the minimum spacer positions is −35.21%. Additionally, the overall variation in the area ratio R between the maximum and minimum spacer positions is −51.18%. As should be appreciated, the comparative biosensor 200 exhibits much greater variations in the area ratio R between the effective electrode areas A_(c), A_(w) compared to the biosensor 10 as the position/placement of the inner boundary of the capillary chamber is varied due to tolerance levels associated with manufacturing of the biosensor. Accordingly, it should be appreciated that the comparative biosensor 200 does not exhibit the same improvements in precision and/or accuracy as the biosensor 10.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected.

It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary. 

What is claimed is:
 1. A plurality of biosensors, comprising: at least a first biosensor and a second biosensor each including: a capillary chamber including an inner side wall; a working electrode including an effective working electrode portion positioned within the capillary chamber, the effective working electrode portion defining an effective working electrode area exposed to the capillary chamber and including a first working electrode portion and a working electrode neck extending from the first working electrode portion, wherein: the working electrode neck includes a working electrode neck width and the working electrode neck width is reduced relative to an average width of the first working electrode portion; the working electrode neck extends out of the capillary chamber and a remainder of the effective working electrode portion is positioned entirely in the capillary chamber; and the inner side wall is positioned along the working electrode neck; and a counter electrode including an effective counter electrode portion positioned within the capillary chamber, the effective counter electrode portion defining an effective counter electrode area exposed to the capillary chamber and including a first counter electrode portion and a counter electrode neck extending from the first counter electrode portion, wherein: the counter electrode neck extends out of the capillary chamber and a remainder of the effective counter electrode portion is positioned entirely in the capillary chamber; the inner side wall is positioned along the counter electrode neck; and the counter electrode neck includes a counter electrode neck width, and the working electrode neck width is less than the counter electrode neck width; wherein relative positioning of the inner side wall along the working electrode neck in the first biosensor is different than relative positioning of the inner side wall along the working electrode neck in the second biosensor, and a ratio between the effective counter electrode area and the effective working electrode area in the first biosensor corresponds to a ratio between the effective counter electrode area and the effective working electrode area in the second biosensor.
 2. The plurality of biosensors of claim 1, wherein the counter electrode neck width is reduced relative to an average width of the first counter electrode portion of the effective counter electrode portion.
 3. The plurality of biosensors of claim 1, wherein the effective working electrode area is different than the effective counter electrode area.
 4. The plurality of biosensors of claim 1, wherein the working electrode neck width is no more than one-half of the counter electrode neck width.
 5. The plurality of biosensors of claim 1, wherein the capillary chamber includes an open first end, a closed second end defined by the inner side wall, and a pair of lateral sidewalls extending between the open first end and the closed second end.
 6. The plurality of biosensors of claim 1, wherein a first ratio between the effective working electrode area and the working electrode neck width is substantially equal to a second ratio between the effective counter electrode area and the counter electrode neck width.
 7. The plurality of biosensors of claim 6, wherein the effective working electrode area is less than the effective counter electrode area.
 8. The plurality of biosensors of claim 1, wherein the effective working electrode area is less than the effective counter electrode area.
 9. The plurality of biosensors of claim 1, wherein the first biosensor and the second biosensor each further includes a support substrate including a first inner surface with the working and counter electrodes extending along the first inner surface, and a spacer substrate including a first face and an opposite second face, wherein the spacer substrate defines an inner boundary of the capillary chamber and the first face of the spacer substrate is attached to the first inner surface of the support substrate.
 10. The plurality of biosensors of claim 9, wherein the first biosensor and the second biosensor each further includes a cover substrate including a second inner surface attached to the second face of the spacer substrate, wherein the capillary chamber is defined by overlapping portions of the first inner surface of the support substrate and the second inner surface of the cover substrate in combination with the inner boundary defined by the spacer substrate.
 11. The plurality of biosensors of claim 9, wherein the spacer substrate includes a channel extending therethrough from the first face to the opposite second face, the channel defining the inner boundary of the capillary chamber.
 12. The plurality of biosensors of claim 9, wherein the support substrate has a length dimension extending generally along a longitudinal axis and a width dimension extending generally along a transverse axis, and wherein the working electrode neck and the counter electrode neck each extend in a direction generally along the longitudinal axis.
 13. The plurality of biosensors of claim 9, wherein the support substrate has a length dimension extending generally along a longitudinal axis and a width dimension extending generally along a transverse axis, and wherein the inner side wall extends generally along the transverse axis.
 14. The plurality of biosensors of claim 13, wherein the first working electrode portion extends generally along the transverse axis and the working electrode neck extends from the first working electrode portion generally along the longitudinal axis.
 15. The plurality of biosensors of claim 14, wherein the first counter electrode portion includes a loop body extending peripherally about the first working electrode portion and the counter electrode neck extends from the loop body generally along the longitudinal axis.
 16. The plurality of biosensors of claim 1, further comprising a vial containing the first biosensor and the second biosensor.
 17. The plurality of biosensors of claim 1, wherein the first biosensor and the second biosensor are removably coupled to one another.
 18. The plurality of biosensors of claim 1, wherein the first biosensor and the second biosensor are arranged in a coil, magazine, blister packaging, or card with a number of additional bio sensors.
 19. A plurality of biosensors, comprising: at least a first biosensor and a second biosensor each including: a capillary chamber including an inner boundary; a working electrode partially positioned in the capillary chamber and defining a first area corresponding to a working electrode portion positioned in the capillary chamber, the working electrode including a working electrode neck extending from the capillary chamber past the inner boundary and having a working electrode neck width which is reduced relative to an average width of a remainder portion of the working electrode in the capillary chamber; a counter electrode partially positioned in the capillary chamber and defining a second area corresponding to a counter electrode portion positioned in the capillary chamber, the counter electrode including a counter electrode neck extending from the capillary chamber past the inner boundary, and the counter electrode neck including a counter electrode neck width; wherein the first area in the first biosensor is greater than the first area in the second biosensor and a ratio between the second area and the first area in the first biosensor corresponds to a ratio between the second area and the first area in the second bio sensor; and wherein the working electrode neck width is reduced relative to the counter electrode neck width.
 20. The plurality of biosensors of claim 19, wherein only the working electrode neck of the working electrode extends from the capillary chamber past the inner boundary and only the counter electrode neck of the counter electrode extends from the capillary chamber past the inner boundary.
 21. The plurality of biosensors of claim 19, wherein positioning of the inner boundary relative to the working electrode neck is different between the first bio sensor and the second biosensor.
 22. The plurality of biosensors of claim 19, wherein an area of the capillary chamber is different between the first biosensor and the second biosensor.
 23. The plurality of bio sensors of claim 19, wherein the remainder portion of the working electrode extends transversely to the working electrode neck.
 24. The plurality of biosensors of claim 19, wherein the capillary chamber includes a first sidewall defining the inner boundary at a first end, and a pair of lateral sidewalls extending from the first sidewall to an open second end.
 25. A method, comprising: positioning a first spacer substrate over a first support substrate and partially covering a working electrode and a counter electrode positioned on the first support substrate to provide a first exposed working electrode area and a first exposed counter electrode area; positioning a second spacer substrate over a second support substrate and partially covering a working electrode and a counter electrode positioned on the second support substrate to provide a second exposed working electrode area and a second exposed counter electrode area, wherein the second exposed working electrode area is different than the first exposed working electrode area; and maintaining a constant balance between a ratio between the first exposed counter electrode area and the first exposed working electrode area and a ratio between the second exposed counter electrode area and the second exposed working electrode area; wherein the working electrode on the first support substrate includes a neck having a reduced width relative to an average width of a remainder portion of the working electrode on the first substrate in the first exposed working electrode area, the working electrode on the second support substrate includes a neck having a reduced width relative to an average width of a remainder portion of the working electrode on the second substrate in the second exposed working electrode area and the width of the working electrode neck is less than the width of the counter electrode neck.
 26. The method of claim 25, wherein the first and second spacer substrates terminate at a first end positioned over the first exposed portion of the working electrode.
 27. The method of claim 25, wherein: the first spacer substrate terminates at a first end, the first support substrate terminates at a first end, and a first distance extends between the first ends of the first support substrate and the first spacer substrate; the second spacer substrate terminates at a first end, the second support substrate terminates at a first end, and a second distance extends between the first ends of the second support substrate and the second spacer substrate; and the first distance is different than the second distance.
 28. The method of claim 25, wherein: the first and second spacer substrates terminate at a first end and include a pair of lateral sidewalls extending from the first end; and the first and second exposed working electrode areas and the first and second exposed counter electrode areas are positioned between the first end and the lateral sidewalls.
 29. The method of claim 25, further comprising positioning a first cover substrate over the first spacer substrate and positioning a second cover substrate over the second spacer substrate.
 30. A method, comprising: positioning a spacer substrate over a support substrate and partially covering a working electrode and a counter electrode positioned on the support substrate to provide an exposed working electrode area and an exposed counter electrode area, wherein: the working electrode includes an exposed working electrode neck extending from a remainder exposed portion of the working electrode, the working electrode neck having a reduced width relative to an average width of the remainder exposed portion of the working electrode; the counter electrode includes an exposed counter electrode neck extending from a remainder exposed portion of the counter electrode, the counter electrode neck having a width which is greater than the width of the working electrode neck; and the spacer substrate is positioned at one of a number of positions along the working electrode neck, wherein the exposed counter electrode area and the exposed working electrode area are different for each of the number of positions while a ratio between the exposed counter electrode area and the exposed working electrode area remains constant regardless of the position.
 31. The method of claim 30, wherein the spacer substrate is positioned along the counter electrode neck.
 32. The method of claim 30, further comprising positioning a cover substrate over the spacer substrate. 